Project Car - Supercharge Your '05 To '10 Mustang

Ccrp 1109 Charger Install Supercharge Your 2005 To 2010 Mustang 001

When the '05 S197 Mustang arrived, it appeared on every 8x10 square piece of advertisement short of a Wheaties box. It looked right, sounded right, and seemed like the ultimate solution to the weird-ish New Edge SN-95s that preceded it. Then, ouch, the 4.6 3V only made 300 hp and 330 lb-ft, and the convertible version weighed around 3,600 pounds. The car had everything but speed.

Six years later, there are plenty of these Mustangs just waiting for modification. We snagged an '06 GT and added a set of '10 SVT 19x9.5-inch wheels, 295/30ZR19 Toyo Proxes 4 tires, and a Mustang GT handling pack with SVT brakes.

Now the car is nearly glued to the road and looks killer, but the horse- power war has raged on and 300 hp now comes with the economy, six- cylinder version of just about everything on the road. Our Mustang is no match for LS-powered fifth-gen Camaros or even newer versions of the Mustang GT. Is there no justice? Yes, there is, and it comes from Whipple Superchargers and Ford Racing.

The Options

Ford makes it easy by offering only two supercharger systems for the '05 to '10 3V Mustang GT. The 400hp kit comes with a 2.3L (140-cid) Whipple twin-screw supercharger and all the hardware to get it on the car. If it is installed by a Ford dealer, it will hold the car's warranty. The 550hp Big Boost kit comes with a smaller pulley, an air-to-water intercooler, special calibration, and a new dual fuel pump. The kits are for manual Mustangs only. If you have an automatic, there is a 475hp version for you.

The blower packages are more than just a bunch of parts that happen to fit together. Ford tested them on an engine dyno to map all the engine parameters before subjecting the engine to full power pulls from 30 to 110 degrees F. Then the engines go into a car where they are similarly brutalized in a climate-controlled, wind- tunnel dyno, where hundreds of pulls are made to simulate changes in elevation, air quality, and temperature. Then the cars are driven more than 4,000 miles. This is all to get a calibration validation and a 50-state-legal EO number. For a well-tested, street-legal 550 hp that you just bolt on, it's hard to beat the price.

Badass

Punch it and you get that slide-whistle shriek and plenty of smoke and fun with the traction control off. (Shhhhh, if you don't stomp it open, the boost bypass makes the car act and sound like a stock, 300hp GT.) Midrange torque is excellent, so there are no cars you can't pass and there is no lane you can't own. We think the traction control is a bit of a mother hen, however, when it cuts the throttle on bumpy roads at WOT and limits the rpm to 6,375, even with the glee button in the Off position. We curse it when we are in the mood for mayhem and thank it when we have to commute on Monday morning and nothing is broken.

At this point the car feels fast enough to get into trouble, but that doesn't stop us from wanting to go faster. To do so, we need more cam, more heads, and enough connecting rod to handle 7,500 rpm. These parts exist in the form of the Aluminator. It is a short-block with a forged Cobra rotating assembly and forged 8.5:1 pistons. Adding the ported heads and hot rod cams would easily push us over the 500-rwhp mark, likely to the detriment of the drivetrain and catalytic converters. We recommend the Aluminator swap and Big Boost kit. You won't be disappointed.

RWHP
Avg.	Supercharged	Stock
RPM	HP	TQ	HP	TQ
3,100	178	300	153	257
3,200	212	346	158	257
3,300	236	371	163	259
3,400	245	377	170	261
3,500	263	390	177	266
3,600	272	396	186	270
3,700	288	404	192	272
3,800	294	406	197	273
3,900	305	407	204	275
4,000	311	408	209	275
4,100	324	411	216	274
4,200	329	411	222	276
4,300	339	410	228	277
4,400	344	409	233	276
4,500	355	410	236	274
4,600	360	410	239	271
4,700	369	409	242	270
4,800	373	407	245	268
4,900	383	407	249	266
5,000	388	407	254	264
5,100	398	407	255	262
5,200	403	406	257	259
5,300	411	405	257	255
5,400	414	402	257	249
5,500	417	395	259	247
5,600	423	393	259	242
5,700	426	391	259	239
5,800	429	385	259	234
5,900	431	379
6,000	434	378

Parts
Description	Source	PN	Price
'05 to '10 Mustang radiator	Be Cool	60205	$678.99
Big Boost supercharger kit	Ford Racing	M-6066-M11	6,995.00
Blue-coated valve covers	Ford Racing	M-6582-3VB	269.00

The twin-screw Whipple only appeared from the factory on the Ford GT. The GT500 and Cobras use the lobe-style blower with 60-degree twist, making the twin-screw a killer upgrade for a street car.
The twin-screw Whipple only appeared from the factory on the Ford GT. The GT500 and Cobras
This job is essentially a manifold swap and a pulley change. The kit comes with a 97-page, photo-driven instruction guide, so we are just going to cover the highlights.
This job is essentially a manifold swap and a pulley change. The kit comes with a 97-page,
The factory steel idler pulley and tensioner require grinding to remove the stop. Both new idler pulleys are supplied with the kit, and it’s the only real fabrication required—if you want to call it that.
The factory steel idler pulley and tensioner require grinding to remove the stop. Both new

We thought this would be a good time to swap the crusty aluminum valve covers for these blue ones from Ford Racing. You might have seen them on the hot rod crate version of the 3V.
We thought this would be a good time to swap the crusty aluminum valve covers for these bl
The fact that the supercharger can be removed from the manifold made the installation and torque wrenching way easier, and it eliminated the iron-manifold hernia.
The fact that the supercharger can be removed from the manifold made the installation and
Left: The dual fuel pump is mounted under the passenger-side rear seat and comes with its own harness and driver that mounts in the trunk.
Left: The dual fuel pump is mounted under the passenger-side rear seat and comes with its

Inside the manifold hides the intercooler. Water is pumped through what is essentially a square radiator from a separate system that cools the air charge before it enters the intake ports.
Inside the manifold hides the intercooler. Water is pumped through what is essentially a s
With the new manifold installed, it’s just a matter of dropping the supercharger in the hole. What’s the best part about late-model parts? No RTV, alignment, or gasket issues.
With the new manifold installed, it’s just a matter of dropping the supercharger in the ho
The injectors also need to be swapped and are included in the kit.

This is the giant rubber grommet that covers the fuel pump. We created the hole on the left to feed the new harness to the pump.
This is the giant rubber grommet that covers the fuel pump. We created the hole on the lef
This is the heat exchanger for the intercooler. It mounts in front of the radiator, so we had to pull off the front end of the car. Block off a day for this one.
This is the heat exchanger for the intercooler. It mounts in front of the radiator, so we
Finally, the system comes with its own cold-air kit and filter. It mounts on the front left of the engine compartment. Note the intercooler reservoir mounted behind it.
Finally, the system comes with its own cold-air kit and filter. It mounts on the front lef

To give us an advantage at the track in the hot SoCal summer, we upgraded the stock radiator to this gigantic cooler from Be Cool. We’ve since baked this car in 100-degree traffic without any problems.
To give us an advantage at the track in the hot SoCal summer, we upgraded the stock radiat
The intercooler is part of a closed system and has its own pump. It is mounted behind the bumper and circulates water to a reservoir under the hood.
The intercooler is part of a closed system and has its own pump. It is mounted behind the
This is a 50-state-legal kit, so we left the factory throttle-body and exhaust manifolds alone.
This is a 50-state-legal kit, so we left the factory throttle-body and exhaust manifolds a

Right: If you fear computers and tuning, don’t worry: The ProCal from Ford comes preprogrammed for this kit. All you have to do is press a few buttons and it saves the stock cal in the computer and uploads the new one. The whole tuning process fits into one caption.
Right: If you fear computers and tuning, don’t worry: The ProCal from Ford comes preprogra
Before the Ford Racing supercharger kit.
After the Ford Racing supercharger kit.